Actuator for spray container and method regarding same

ABSTRACT

Actuator apparatus for spray containers and methods of manufacturing actuator apparatus for spray containers. The actuator apparatus includes a cover having a restraint structure, e.g., locatable below an aperture portion of a push button of a base, to restrict the push button from depression by a user when the actuator apparatus is in a locked position.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of “U.S. Provisional ApplicationSer. No. 61/103,059 filed 6 Oct. 2008, entitled “ACTUATOR FOR SPRAYCONTAINER,” which is incorporated herein by reference in its entirety.

BACKGROUND

The disclosure herein relates generally to actuators for spraycontainers and methods of manufacturing actuators for spray containers.

Spray containers containing many different components or contents suchas, e.g., paint, adhesives, corrosives, lubricants, insect repellents,hairsprays, creams, edibles, foams, etc. have been marketed for manyhousehold, commercial, and industrial purposes.

In certain conventional spray containers, an actuator apparatus mayinclude a tubular valve stem element biased into a closed positionwhich, when depressed into the body of the container opens the valve andreleases the contents which are held under pressure. When the appliedforce at the valve stem is removed, the valve stem returns to its closedposition simultaneously stopping the outward flow of the pressurizedcontents of the container. For example, in one type of spray container,the actuator apparatus may include a button fitted directly over thevalve stem such that when the button is depressed, the valve stem issimultaneously depressed or tilted against a spring bias causing thecontents of the container to be released via an outlet. Release of thepressure at the button returns the valve stem to its equilibriumposition. Often, a protective cover is fitted over the top of the spraycontainer covering the actuator apparatus and is removed before use.Such protective covers may then be placed back over the actuatorapparatus, e.g., for safe storage.

In another type of spray container, an actuator apparatus may include acap having a button or trigger. By depressing the button or trigger, thecontents of the spray container may be sprayed, e.g., through an openingin the cap. Often, the button or trigger is not protected fromaccidental depression by a user.

Lockable actuator apparatuses have been described. For example, U.S.Pat. No. 6,523,722 to Clark et al., U.S. Pat. App. Pub. No. 2005/0017027to Yerby et al., and U.S. Pat. App. Pub. No. 2007/0039979 to Strand etal. disclose various lockable actuators for spray containers. However,such designs may include many separate components and/or may be toocomplex such that the components and/or complexity may increasemanufacturing problems (e.g., complex multi-piece molds, etc.), whichmay increase the cost of such actuators.

SUMMARY

The disclosure herein relates generally to actuators for spraycontainers and methods of manufacturing actuators for spray containers.

In one embodiment of the actuator apparatus for a spray container, theactuator apparatus includes a base and a cover coupled to the base. Thebase includes a lower portion couplable to the spray container and apush button depressibly attached to the lower portion. The push buttonincludes a body portion, an aperture portion, and a receiver stem forreceiving a valve assembly. The body portion extends along an axis ofthe actuator apparatus between a first end region connectable to thelower portion of the base and a second end region to be contacted fordepression of the push button by a user. The aperture portion extendsradially from a region of the body portion and defines an exit aperture.The receiver stem portion defines an entrance aperture. A fluidpassageway extends between the entrance aperture and the exit aperture.Further, the push button is movable relative to the lower portion of thebase between at least a normal position and a depressed position. Whenthe push button is in the depressed position, the push button actuatesthe valve assembly to provide a spray through the exit aperture. Thecover defines a push button opening that permits access to the secondend region of the body portion of the push button to allow depression ofthe push button by the user. Further, the cover and the base are movablerelative to each other between at least a locked position such that thepush button is restricted from moving into the depressed position and anunlocked position such that the push button is allowed to move into thedepressed position. The cover further defines a spray opening alignablewith the exit aperture of the aperture portion when the cover is in theunlocked position. Further, the cover includes a restraint structure andthe restraint structure is located below the aperture portion of thepush button of the base to restrict the push button from moving into thedepressed position when the cover is in the locked position.

In another embodiment, the actuator apparatus for a spray containerincludes a base and a cover coupled to the base. The base includes alower portion couplable to the spray container and a push buttondepressibly attached to the lower portion. The push button includes abody portion and an aperture portion. The body portion extends between afirst end region connectable to the lower portion of the base and asecond end region to be contacted for depression of the push button by auser. The aperture portion extends radially from a region of the bodyportion. Further, the push button is movable relative to the lowerportion of the base by depression of the push button by the user. Stillfurther, the aperture portion defines an exit aperture. The coverdefines a push button opening that permits access to the second endregion of the body portion to allow depression of the push button by theuser. Also, the cover and the base are rotatably movable relative toeach other between an unlocked position and a locked position. The coverincludes a cylindrical inner wall portion lying parallel to an axis ofthe actuator apparatus and the cylindrical inner wall portion defines atleast a portion of the push button opening. The cover further includes arestraint structure locatable below the aperture portion of the pushbutton of the base to restrict the push button from depression by theuser when in the locked position. Further, at least a portion of therestraint structure is located closer to the axis of the actuatorapparatus than the cylindrical inner wall portion of the cover. Stillfurther, the cover defines a spray opening alignable with the exitaperture by rotating the cover and the base relative to each other whenin the unlocked position.

In one embodiment, a method of manufacturing a cover for an actuatorapparatus having a base including a lower portion and acentrally-located push button depressibly attached to the lower portionis described. The method of manufacturing includes providing a molddefining a cavity for forming the cover. The cover defines acentrally-located push button opening that permits access to the pushbutton of the base when assembled with the base. Further, the coverincludes an inner wall portion, an outer wall portion, and a restraintstructure extending from the inner wall portion. The inner wall portionlies along an axis of the actuator apparatus when assembled with thebase and defines at least a portion of the push button opening. Theouter wall portion is located at a distance further away from the axisthan the inner wall portion when assembled with the base and defines aspray opening. The restraint structure extends from the inner wallportion and at least a portion of the restraint structure is locatedcloser to the axis of the actuator apparatus when assembled than theinner wall portion of the cover. The mold includes a first mold portionand a second mold portion. The first mold portion defines a firstmolding surface corresponding to at least outer and inner wall portionsurfaces of the cover facing a first direction and at least a lowersurface of the restraint structure. The second mold portion defines asecond molding surface corresponding to at least outer and inner wallportion surfaces of the cover facing a second direction opposite fromthe first direction and at least an upper surface of the restraintstructure. The method further includes positioning the first moldportion relative to the second mold portion such that the first moldingsurface of the first mold portion and the second molding surface of thesecond mold portion define the cavity of the mold for forming the coverand introducing moldable material into the cavity of the mold. Stillfurther, the method includes forming the cover from the moldablematerial within the cavity of the mold, moving the first mold portionrelative to the second mold portion for removing the cover from thecavity of the mold, and removing the cover from the cavity of the mold.

The above summary is not intended to describe each embodiment or everyimplementation of the actuator apparatus or methods of manufacturingsuch actuator apparatus. Advantages, together with a more completeunderstanding, will become apparent and appreciated by referring to thefollowing detailed description and claims taken in conjunction with theaccompanying drawings.

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 is a front perspective view of a spray container and an exemplaryembodiment of an actuator apparatus in an unlocked position.

FIG. 2 is a rear perspective view of the spray container and theactuator apparatus of FIG. 1 in the unlocked position

FIG. 3 is a front perspective view of the spray container and theactuator apparatus of FIG. 1 but in a locked position.

FIG. 4 is a rear perspective view of the spray container and theactuator apparatus of FIG. 1 but in a locked position.

FIG. 5 is an exploded, perspective view of the actuator apparatus ofFIG. 1.

FIG. 6 is a perspective view of the base of the actuator apparatus ofFIG. 1.

FIG. 7 is a front view of the base of FIG. 6.

FIG. 8 is a side view of the base of FIG. 6.

FIG. 9 is a rear view of the base of FIG. 6.

FIG. 10 is a top view of the base of FIG. 6.

FIG. 11 is a bottom view of the base of FIG. 6.

FIG. 12 is a front perspective view of the cover of the actuatorapparatus of FIG. 1.

FIG. 13 is a front view of the cover of FIG. 12.

FIG. 14 is a side view of the cover of FIG. 12.

FIG. 15 is a rear view of the cover of FIG. 12.

FIG. 16 is a top view of the cover of FIG. 12.

FIG. 17 is a bottom view of the cover of FIG. 12.

FIG. 18 is a rear perspective view of the cover of FIG. 12.

FIG. 19 is a bottom perspective view of the cover of FIG. 12.

FIG. 20 is a cross-sectional view of the cover of FIG. 16 taken alongline 20-20.

FIG. 21 is a front view of the actuator apparatus of FIG. 1 but in alocked position.

FIG. 22 is a cross-sectional view of the actuator apparatus of FIG. 21taken along line 22-22.

FIG. 23 is top view of the actuator apparatus of FIG. 1 but in a lockedposition.

FIG. 24 is a cross-sectional view of the actuator apparatus of FIG. 23taken along line 24-24.

FIG. 25 is a front view of the actuator apparatus of FIG. 1 in anunlocked position.

FIG. 26 is a cross-sectional view of the actuator apparatus of FIG. 25taken along line 26-26.

FIG. 27 is a top view of the actuator apparatus of FIG. 1 in an unlockedposition.

FIG. 28 is a cross-sectional view of the actuator apparatus of FIG. 27taken along line 28-28 with the push button in a normal position.

FIG. 29 is a cross-sectional view of the actuator apparatus of FIG. 27taken along line 28-28 with the push button in a depressed position.

FIGS. 30A-30C are cross-sectional views illustrating assembly of theactuator apparatus of FIG. 1.

FIG. 31 is a block diagram of a method of manufacturing a cover, e.g.,the cover of FIG. 12, for an actuator apparatus.

The figures are rendered primarily for clarity and, as a result, are notnecessarily drawn to scale.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

In the following detailed description of illustrative embodiments,reference is made to the accompanying figures of the drawing which forma part hereof, and in which are shown, by way of illustration, specificembodiments which may be practiced. It is to be understood that otherembodiments may be utilized and structural changes may be made withoutdeparting from the scope of the disclosure.

A spray container 5 is shown in FIGS. 1-4 extending from a bottomportion 6 to a top portion 7 along an axis 12. An exemplary actuatorapparatus 10 is coupled to the top portion 7 of the spray container 5.The spray container 5 (e.g., a cylindrical spay can) may be any spraycontainer containing a pressurized material that may be actuated by auser to release (e.g., spray) the pressurized contents from an opening.Further, the spray container 5 may contain many different liquidmaterials such as, e.g., paint, adhesives, corrosives, lubricants,insect repellents, hairsprays, creams, edibles, foams, tear gas, pepperspray, and/or any other contents as would be known by one havingordinary skill in the art. Also, the spray container 5 may be formed ofany material capable of containing its contents under pressure, e.g.,metals, polymers, etc.

As shown in FIGS. 1-4, the spray container 5 includes a cylindrical can.Although the spray container 5 depicted in FIGS. 1-4 is cylindrical, theactuator apparatus may be operably coupled to a spray container havingany shape and/or size, e.g., a square container.

Two or more components of the actuator apparatus 10 are movable relativeto each other between two or more different positions. A locked positionis depicted in FIGS. 1-2 while an unlocked position is depicted in FIGS.3-4. In the unlocked position, the actuator apparatus 10 may allow auser to release at least some of the pressurized contents contained inthe spray container 5. In the locked position, the actuator apparatus 10may restrict (e.g., inhibit) a user from releasing the pressurizedcontents contained within the spray container 5.

An exploded view of an exemplary embodiment of the actuator apparatus 10arranged along an axis 12 is depicted in FIG. 5. The actuator apparatus10 may include a base 100, a cover 200, an insert 300, and a valveassembly 400.

The valve assembly 400 may include an actuation valve 402, a flanged cupportion 404, and a tube portion 406. When assembled with the spraycontainer 5, the flanged cup portion 404 may be coupled (e.g., crimped,press-fit, adhered, welded, etc.) to at least a portion of the top ofthe spray container 5, the tube portion 406 may extend into the interiorof the spray container 5, and the actuation valve 402 may extend upwardfrom the top of the spray container 5. The actuation valve 402 andflanged cup portion 404 may further include various structures tooperably couple the actuation valve 402 to a portion of the base suchthat any pressurized contents released through the actuation valve 402flow into a portion of the base 100 (e.g., through passageway 174 asshown in FIG. 28). The flanged cup portion 404 may include acentrally-disposed circular stepped protrusion 408 upon which theactuation valve 402 extends. Such stepped protrusion 408 may includeportions having different diameters that may improve the couplingbetween the valve assembly 400 and the base 100. In at least oneembodiment, the components of the valve assembly 400 may be formed ofthe same material. In other embodiments, the components of the valveassembly 400 may be separate components coupled together.

The actuation valve 402 may be movable to, e.g., release the pressurizedcontents of a spray container (e.g., spray container 5). Such movementof the actuation valve 402 may be downward depression, axially movement,etc.

One having ordinary skill in the art will recognize that other valveconfigurations may be utilized with the apparatus described herein. Forexample, any valve assembly operable by a push button as describedherein to release contents of a spray container may be utilized inconjunction with the actuator apparatus 10 or variations thereof.

The base 100 may include a lower portion 120 and a push button 140 (seeFIGS. 6-11). The push button 140 may be depressibly attached to thelower portion 120. As used herein, “depressibly attached” may refer toattachment such that the push button 140 may be depressed under normalforce by a user to move the push button 140 relative to the lowerportion 120.

The lower portion 120 may include a first end region 121A and a secondend region 121B located further away from the axis 12 than the first endregion 121A. The second end region 121B may be the portion of the base100 that is coupleable to the spray container 5 utilizing, e.g., one ormore protrusions 122 (see FIG. 11) that may facilitate a “snap-fit” tothe top of the spray container 5. Further, the lower portion 120 maydefine a push button aperture 124 located directly below the push button140 to facilitate downward movement of the push button 140 (e.g., suchthat when the push button 140 is depressed, at least a portion of thepush button 140 may be located within the push button aperture 124).

As shown in FIGS. 10-11, the lower portion 120 may include a bridgeportion 126 connecting the lower portion 120 and the push button 140.The bridge portion 126 may be sized and formed of such resilientmaterial that the push button 140 may be depressed to a depressedposition (e.g., movement relative to the lower portion 120) and returnedto a normal position without detaching from the lower portion 120.

Further, the push button 140 may be biased into the normal position suchthat only depression by a user may actuate the valve assembly 400 torelease at least some of the pressurized contents of the spray container5. The bridge portion 126 may provide such bias. In other embodiments,however, the push button 140 may include other componentry (e.g.,springs), materials (e.g., memory foam), and/or structures that may biasthe push button into the normal position.

The lower portion 120 may further include a first female lockingstructure 128, a second female locking structure 130, a spray openingshield portion 132, and deflectable cover retention ribs 134 that willbe described herein in relation to their functions relative to the pushbutton 140 and cover 200.

The push button 140 may include a body portion 142, an aperture portion160, and a receiver stem portion 170 (see FIG. 11). Although depicted asbeing cylindrical, the push button 140 may be any shape and/or sizeoperable to be depressed by a user to actuate a valve assembly, e.g.,valve assembly 400. The push button 140 may be movable relative to thelower portion 120 of the base 100 between at least a normal position anda depressed position. When the push button 140 is in the depressedposition (which is only permitted when the actuator assembly is in theunlocked position), the push button 140 may actuate the actuation valve402 of the valve assembly 400 thereby releasing at least some of thepressurized contents of the spray container 5 through, e.g., an exitaperture 162 of the aperture portion 160 of the push button 140 of thebase 100. When the push button 140 is in the normal position, the valveassembly 402 is not actuated and thereby no pressurized contents arereleased.

The body portion 142 of the push button 140 may extend along an axis 12of the actuator apparatus 10 from a first end region 144 that isconnectable to the lower portion 120 of the base 100, e.g., via thebridge portion 126 of the lower portion 120 of the base 100, to a secondend region 146 that may be contacted (e.g., depressed by a finger) by auser. The second end region 146, as depicted, may define a sloped,concave surface 148, upon which further may be defined spray directionindicia 150 to, e.g., indicate the direction that the pressurizedcontents of the spray container may be released and/or whether theactuator apparatus 10 is in a locked or unlocked position. The sidewallsof the body 142 may cylindrical, e.g., as depicted, and further may beparallel to the axis 12 of the actuator apparatus 10.

The aperture portion 160 may extend radially (e.g., outwardly from theaxis 12 of the actuator apparatus) from a region of the body portion 142(e.g., the side wall thereof) and may define the exit aperture 162. Whenthe pressurized contents are released from the spray container 5, thecontents may be released (e.g., sprayed) through the exit aperture 162.In the embodiment depicted, the aperture portion 160 includes an insertaperture 166 within which the insert 300 is located. The insert 300 maybe a separately manufactured component from the base 100 or may beintegral with the base 100. For example, the insert 300 may be a moldedfeature of the aperture portion 160. As described herein, the insert 300may be a part of the aperture portion 160 of the push button 140 of thebase 100.

Further, at least in one embodiment, the aperture portion 160 extendsalong a portion of the height of the push button body portion 142. Also,the aperture portion 160 may have a lower surface 164 that be contactedby, e.g., a restraint structure (e.g., restraint structure 204 of FIGS.18-19) to restrict the downward movement of the push button 140 asdescribed herein. Although aperture portion 160 is depicted as having alower surface 164 that is flat, the aperture portion 160 may be any sizeand/or shape capable of being contacted by a corresponding restraintstructure (e.g., by restraint structure 204 of FIGS. 18-19) to restrictthe movement of the push button 140.

Further, although in this embodiment, the aperture portion 160 is theportion of the push button 140 that may be contacted by a restraintstructure (e.g., by restraint structure 204) to restrict the movement ofthe push button 140, the aperture portion may be separate from theportion the may be contacted to restrict movement of the push button.For example, in at least one embodiment, the aperture portion may notextend from the push button body portion and instead may be flush withthe exterior of the push button body. In this embodiment, an additionalstructure may extend radially from the push button body portion to becontacted by a restraint structure to restrict the movement of the pushbutton.

The receiver stem portion 170 (see FIG. 11) may receive the valveassembly 400 and may define an entrance aperture 172. A passageway 174may be capable of transmitting gas and/or fluid and may extend from theentrance aperture 172 to the exit aperture 162 of the aperture portion160. When the actuation valve 402 is actuated, the pressurized contentsof the spray container 5 may released and may flow through the valveassembly 400 into the entrance aperture 172, through the passageway 174,and exit through the exit aperture 162.

The base 100 may further include locked and unlocked indicia 102 locatedon various surfaces of its components to indicate to a user what statethe actuator apparatus 10 is in (e.g., unlocked or locked positions).Although the indicia 102 are depictions of a “locked padlock” and an“unlocked padlock,” any indicia including graphics and/or text that maybe capable of indicating to a user the state of the actuator apparatusmay be included on the actuator apparatus. For example, the sprayopening shield portion 132 may extend upwardly from the base 100 and mayinclude such indicia 102. In this embodiment, the spray opening shieldportion 132 has indicia 102 indicating that the actuator apparatus 10 isin a locked state, which is only viewable to user when the actuatorapparatus 10 is actually in a locked state or position as describedherein.

In one or more alternate embodiments, the spray opening shield portion132 may not be used. Rather, the locked indicia may be provided on thepush button body portion 142 such that it shows through the opening 208when the apparatus is in a locked position.

The cover 200, or shroud, may be coupled to the base 100 and alignedalong an axis 12 of the actuator apparatus 10. The cover 200 may definea push button opening 202 (e.g., along axis 12) that permits access tothe second end region 146 of the push button 140 to allow depression(e.g., by a finger) of the push button 140 by a user when the base 100and the cover 200 are assembled together (see, e.g., FIGS. 1-2, 25, &27-29).

The cover 200 (as shown in FIGS. 12-20) may be coupled (e.g., rotatablycoupled) to the base 100 to allow movement there between. At least inone embodiment, the cover 200 is rotatable relative to the base 100between a locked position such that the push button 140 is restrictedfrom moving into the depressed position and an unlocked position suchthat the push button 140 may be allowed to move into the depressedposition. The cover 200 may include a restraint structure 204 thatrestricts the push button 140 from moving into the depressed positionwhen the base 100 and/or cover 200 is in the locked position. Further,the restraint structure 204 may define an upper surface 206 and a lowersurface 209 (see FIG. 19). When the base 100 and/or cover 200 is in thelocked position, the restraint structure 204 may be located below theaperture portion 160 of the push button 140 of the base 100 tophysically restrict the aperture portion 160 from moving downwardly,which in turn restricts the other portions of the push button 140 frommoving into the depressed position. In other words, the upper surface206 of the restraint structure 204 may directly contact the lowersurface 164 of the aperture portion 160 of the push button 140 of thebase 100 to restrict the movement of the push button 140 into thedepressed position.

In at least one embodiment, the cover 200 may include one or morerestraint structures. However, as depicted, the cover 200 includes onlyone restraint structure 204.

The cover 200 may further define a spray opening 208 that may bealignable with the exit aperture 162 of the aperture portion 160 of thepush button 140 of the base 100 when the cover 200 is in the unlockedposition. The cover 200 may further include an inner wall portion 210lying along the axis 12 of the actuator apparatus 10 and an outer wallportion 230 located further away from the axis 12 than the inner wallportion 210. The inner wall portion 210 may further include insidesurface 222 and an exterior surface 224. The inner wall portion 210, asdepicted, may by cylindrical to, e.g., define at least a portion of thepush button opening 202. In other embodiments, however, the inner wallportion 210 may be any shape or size to accommodate and permitdepressible movement of at least a portion of the push button 140.Further, the restraint structure 204 may be located closer to the axis12 of the actuator apparatus 10 than the inner wall portion 210 (seeFIG. 16).

The inner wall portion 210 of the cover 200 may further define a firststop surface 212 and a second stop surface 214. The first stop surface212 may be operable with the aperture portion 160 of the base 100 tostop the cover 200 and base 100 from moving (e.g., rotating about axis12) past the unlocked position. For example, a first side surface 165Aof the aperture portion 160 may contact the first stop surface 212 tostop the cover 200 from rotating relative to the base 100. When thefirst side surface 165A of the aperture portion 160 contacts the firststop surface 212, the aperture apparatus 10 is in the unlocked position.

The second stop surface 214 may be operable with the aperture portion160 of the base 100 to stop the cover 200 and base 100 from moving pastthe locked position. For example, a second side surface 165B of theaperture portion 160 may contact the second stop surface 214 to stop thecover 200 from rotating relative to the base 100. When the second sidesurface 165B of the aperture portion 160 contacts the second stopsurface 214, the aperture apparatus 10 is in the locked position.

The outer wall portion 230 may further define interior surface 242 andexterior surface 244. Further, the outer wall portion 230 may include amale locking structure 232 located on a portion of the interior surface242 of the outer wall portion 230. The male locking structure 232 mayengage either of the first female locking structure 128 (when in thelocked position) or the second female locking structure 130 (when in theunlocked position) of the base 100 when the base 100 and the cover 200are assembled to form the actuator apparatus 10.

Each of the female locking structures 128, 130 may include a first rib129A, 129B and second rib 131A, 131B, respectively. Each rib 129A, 129B,131A, 131B may extend outwardly from the lower portion 120 of the base100 for engagement with the male locking structure 232 of the outer wallportion 230 of the cover 200.

The male locking structure 232 of the outer wall portion 230 of thecover 200 may include a deflectable portion 234 for deflectably engagingthe first rib 129A of the first female locking structure 128 of thelower portion 120 of the base 100 when the cover 200 is moving into thelocked position (e.g., such as to make a “click” when moving into thelocked position) and for deflectably engaging the first rib 129B of thesecond female locking structure 130 of the lower portion 120 of the base100 when the cover 200 is moving into the unlocked position (e.g., suchas to make a “click” when moving into the unlocked position). Thedeflectable portion 234 may deflect to provide resistance to moving thecover 200 relative to the base 100 so as to signal or indicate to a userthat the cover 200 may almost be moved (relative to the base 100) intoeither a locked or unlocked position. The cover 200 may be movedrelative to the base 100 until the deflectable portion 234 deflects overor past one of the first ribs 129A, 129B of the first and the secondfemale locking structures 128, 130, which provides some restriction inmoving the cover 200 relative to the base 100 in the opposite directionsuch that a user may not inadvertently lock or unlock the actuatorapparatus 100.

The male locking structure 232 of the outer wall portion 230 of thecover may further include a rigid portion 236 for engaging the secondrib 131A of the first female locking structure 128 of the base 100 whenthe cover 200 is moved into the locked position to stop the cover 200from moving (e.g., relative to the base 100) past the locked positionand for engaging the second rib 131B of the second female lockingstructure 130 of the base 100 when the cover 200 is moved into theunlocked position to stop the cover from moving (e.g., relative to thebase 100) past the unlocked position. The rigid portion 236 may engagethe second ribs 131A, 131B so as to stop the cover 200 from movingrelative to the base 100 any farther. As a result, the male lockingstructure 232 may be sandwiched between either the first rib 129A andthe second rib 131A of the first female locking structure 128 or thefirst rib 129B and the second rib 131B of the second female lockingstructure 130 to be partially restrained/inhibited such that a user maynot inadvertently lock/unlock the actuator apparatus 100 or move (e.g.,rotate) the cover 200 relative to the base 100 further past either theunlocked or locked positions.

The cover 200 may further include an annular flange 216 located on theinterior surface of the outer wall portion 230 of the cover 200extending inwardly towards the axis 12 of the actuator apparatus 10 foruse in coupling the cover 200 to the base 100 utilizing, e.g., thedeflectable cover retention ribs 134 of the lower portion 120 of thebase 100. The annular flange 216 may include an upper surface 218 (e.g.,facing upwardly) and a lower surface 220 (e.g., facing downwardly), andeach deflectable cover retention rib 134 may include an outer surface136 (e.g., facing away from axis 12) and a bottom surface 138 (e.g., asurface orthogonal to axis 12).

The base 100 and the cover 200 may be coupled together by aligning thebase 100 and the cover 200 along an axis 12 with the cover 200positioned above the base 100 (see FIG. 5). The base 100 and cover 200may be moved towards each such that the push button 140 of the base 100extends at least partially into the push button aperture 124 (see FIG.30A). Further, the base 100 and the cover 200 are movable relative toeach other between at least a pre-coupled position (see FIG. 30B), wherethe cover 200 not yet coupled to the base 100 but in contact thereof,and a coupled position (see FIG. 30C), where the cover 200 is coupled tothe base 100. When in the pre-coupled position (see FIG. 30B), the lowersurface 220 of the annular flange 216 of the cover 200 may contact theouter surface 136 of the deflectable cover retention rib 134 to deflectthe deflectable cover retention rib 134 away from its normal position.When in the coupled position (see FIG. 30C), the cover 200 is “snapped”past the pre-coupled position. In the coupled position, the uppersurface 218 of the annular flange 216 of the cover 200 may engage thebottom surface 138 of the deflectable cover retention rib 134 to retainthe cover 200 to the base 100. An annular gap 139 may further be definedbetween the bottom surface 138 of the cover retention rib 134 and thelower portion 120 of the base 100. The annular gap 139 may receive theannular flange 217 of the cover 200 to allow the cover and the base tomove relative each other about the axis 12 of the actuator apparatus100.

The cover 200 and base 100 may be in the form of one or more alternateconfigurations to accomplish the coupling therebetween. For example, theannular flange of the cover may project outward and away from axis 12 asopposed to inward and an annular retention rib of the base may extendinward towards axis 12 (e.g., at the top of the lower portion 120 ofbase 100) to engage the annular flange of the cover thereunder whensnapped into place. One will recognize that such snap coupling may beimplemented by a variety of base and cover mating configurations.

Further, although the upper surface 218 and the lower surface 220 of theannular flange 216 converge at a point creating an edge as depicted, theupper surface 218 and the lower surface 220 may converge in a rounded orless-steep angle such that the annular flange 216 has a rounded surfacefacing the axis 12 of the actuator apparatus 10.

As described herein, the base 100 and the cover 200 may be movable(e.g., rotatably movable) relative to each between the locked andunlocked positions. In at least one embodiment, the base 100 is fixedrelative to the spray container 5, and the cover 200 is rotatablerelative to the base 100 between the locked and unlocked positions. Inat least another embodiment, the cover 200 is fixed relative to thespray container 5, and the base 100 is rotatable relative to the cover200 between the locked and unlocked positions. In this embodiment, thecover 200 may include additional structure to secure the cover 200 tothe spray container 5 (e.g., structure that extends around the outsideof the lower portion 120 of the base 100 or structure that extendsthrough the push button aperture 124 of the base 100).

As described herein, the base 100 and cover 200 of the actuatorapparatus 10 are movable relative to each other between a lockedposition and an unlocked position. Different views of the actuatorapparatus 10 in the locked position are shown in FIGS. 21-24. Further,different views of the actuator apparatus 10 in the unlocked positionare shown in FIGS. 25-29.

As depicted in the front view of the actuator apparatus 10 in FIG. 21,the spray opening shield portion 132 of the base 100 may be covering atleast a portion (e.g., most) of the spray opening 208 of the cover 200.Locked indicia 102 may be viewable through the spray opening 208 toindicate to a user that the actuator apparatus 10 is in a lockedposition.

As depicted in the cross-sectional view of the actuator apparatus 10 inFIG. 22, the restraint structure 204 of the cover 200 is located beneaththe aperture portion 160 of the push button 140 of the base 100 torestrict the push button 140 from depression (i.e., the lockedposition). Further, the male locking structure 232 of the cover 200 isengaged with the first female locking structure 128 of the base 100. Inthis view, the male locking structure 232 can been seen sandwichedbetween the first rib 129A and second rib 131A of the first femalelocking structure 128.

When the base 100 and the cover 200 is assembled to form the actuator10, a gap 26 may exist between the push button 140 and the inner wallportion 210 of the cover 200 as shown in FIG. 23. A portion 207 of therestraint structure 204 may be seen in the gap 26 that does not extendbeneath the aperture portion 160 of the push button 140 of the base 100.This portion 207 of the restraint structure 204 may further providesupport to the restraint structure 204 and may engage the second sidesurface of the 165B of the aperture portion 160 of the push button 140of the base 100 when in the locked position to, e.g., stop the base 100and/or cover 200 from moving further past the locked position. Further,this view shows that at least a portion of the restraint structure 204may be located closer to the axis 12 of the actuator apparatus 10 thanthe inner wall portion 210 of the cover 200.

Another view of the actuator apparatus 24 in the locked position may beshown in FIG. 24. In this view, the upper surface 206 of the restraintstructure 204 of the cover may be shown to engage the lower surface 164of the aperture portion 160 of the push button.

The actuator apparatus 10 is shown in the unlocked position in FIGS.25-29. The front view of the actuator apparatus 10 as depicted in FIG.25 shows that the aperture portion 160 may be viewable through the sprayopening 208 of the cover 200 when the actuator apparatus 10 is in theunlocked position. The cross-sectional view of the actuator apparatus 10as depicted in FIG. 26 further shows the aperture portion 160 alignedwith the spray opening 208. Further, the male locking structure 232 ofthe cover 200 is shown to be engaged with the second female lockingstructure 130 of the base. In this view, the male locking structure 232can been seen sandwiched between the first rib 129B and second rib 131Bof the second female locking structure 130.

As depicted in FIG. 27, the restraint structure 204 including portion207 may be seen in the gap 26 about a 90 degrees around the axis 12 fromthe spray opening 208 of the cover 200 such as to not impede or inhibitthe depressible movement of the push button 140 and/or aperture portion160. Further, the exit aperture 162 of the aperture 160 is aligned withthe spray opening 208 (see FIG. 28) such that contents that may bereleased through the exit aperture 162 may further exit through thespray opening 208.

The push button 140 is shown to be in the normal position as shown inFIG. 28 and in the depressed position in FIG. 29. When the push button140 is in the depressed position (e.g., a user may depress the pushbutton 140 with their finger), the receiver stem portion 170 of the pushbutton 140 of the base 100 may actuate the actuation valve 402 of thevalve assembly 400 (not shown in FIGS. 28-29) to release at least someof the pressurized contents of the spray container 5. When the pushbutton 140 is no longer being depressed, the push button 140 may move(e.g., resiliently move) back to the normal position as shown in FIG.28.

In at least this embodiment, the push button 28 when depressed may pivot(e.g., about 1 degree to about 45 degrees) about an axis 15 extendingthrough the bridge portion 126 of the base 100 (see FIG. 29). In otherembodiments, the push button may move differently than pivotally, e.g.,downwardly.

Although in this embodiment the bridge portion 126 of the base 100 isthe portion of the base 100 that biases the push button 140 in thenormal position, in other embodiments additional components may beincluded to bias the push button 140 in the normal position (e.g.,springs, memory foam, etc.).

Further, the components of the actuator apparatus 10, e.g., the cover200 or base 100, may be formed of polymers, polypropylene, or any othermaterial or combination of materials as known by one having ordinaryskill in the art.

Still further, the cover 100 and the base 200 of the actuator apparatus10 may be manufactured through any molding process as known by onehaving ordinary skill in the art, e.g., injection molding, transfermolding, compression molding, etc. In at least one embodiment, the cover100 and the base 200 may be formed using a two-piece mold. In otherembodiments, the components of the actuator apparatus 10 may be formedusing various two or more piece molds as well as other manufacturingtechniques.

For example, a method 600 of manufacturing a cover (e.g., cover 200) foran actuator apparatus is shown in FIG. 31. In at least this embodiment,the actuator apparatus may have a base that may include a lower portionand a centrally-located push button depressibly attached to the lowerportion.

The method 600 may include providing a mold (block 602). The mold maydefine a cavity for forming the cover. In at least this embodiment, thecover may be similar to the cover 200 shown in FIGS. 12-20. For example,the cover may define a centrally-located push button opening thatpermits access to the push button of the base when assembled with thebase. Further, the cover may include an inner wall portion lying alongan axis of the actuator apparatus when assembled with the base. Theinner wall portion of the cover may define at least a portion of thepush button opening and an outer wall portion may be located a distancefurther away from the axis than the inner wall portion when assembledwith the base. Further, the outer wall portion of the cover may define aspray opening. The restraint structure may extend from the inner wallportion and at least a portion of that restraint structure may belocated closer to the axis of the actuator apparatus when assembled thanthe inner wall portion of the cover.

Providing a mold (block 602) may include providing a first mold portion(block 604) and providing a second mold portion (block 606). The firstmold portion may define a first molding surface corresponding to atleast outer and inner wall portion surfaces of the cover facing a firstdirection and at least a lower surface of the restraint structure. In atleast one embodiment using the cover 200, for example, the first moldingsurface may correspond to the interior surface 242 of the outer wallportion 230, the exterior surface 224 of the inner wall portion 210, andthe lower surface 209 of the restraint structure 204.

The second mold portion may define a second molding surfacecorresponding to at least outer and inner wall portion surfaces of thecover facing a second direction opposite from the first direction and atleast an upper surface of the restraint structure. In at least oneembodiment using the cover 200, for example, the first molding surfacemay correspond to the exterior surfaces 244 of the outer wall portion230, the interior surface 222 of the inner wall portion 210, and theupper surface 206 of the restraint structure 204.

The method 600 may further include positioning the first mold portionrelative to the second mold portion (block 608) such that the firstmolding surface of the first mold portion and the second molding surfaceof the second mold portion define the cavity of the mold for forming thecover. Still further, the method may include introducing moldablematerial into the cavity of the mold (block 610) and forming the coverfrom the moldable material within the cavity of the mold (block 612).And still further, the method may include moving the first mold portionrelative to the second mold portion for removing the cover from thecavity of the mold (block 614), and removing the cover from the cavityof the mold (block 616).

The complete disclosure of the patents, patent documents, andpublications cited in the Background, the Detailed Description ofExemplary Embodiments, and elsewhere herein are incorporated byreference in their entirety as if each were individually incorporated.

Illustrative embodiments of this invention are discussed and referencehas been made to possible variations within the scope of this invention.These and other variations, combinations, and modifications in theinvention will be apparent to those skilled in the art without departingfrom the scope of the invention, and it should be understood that thisinvention is not limited to the illustrative embodiments set forthherein. Accordingly, the invention is to be limited only by the claimsprovided below and equivalents thereof.

1. An actuator apparatus for a spray container, wherein the actuatorapparatus comprises: a base comprising: a lower portion couplable to thespray container; and a push button depressibly attached to the lowerportion, wherein the push button comprises: a body portion extendingalong an axis of the actuator apparatus between a first end regionconnectable to the lower portion of the base and a second end region tobe contacted for depression of the push button by a user; an apertureportion extending radially from a region of the body portion, whereinthe aperture portion defines an exit aperture; and a receiver stemportion for receiving a valve assembly, wherein the receiver stemportion defines an entrance aperture, wherein a fluid passageway extendsbetween the entrance aperture and the exit aperture, wherein the pushbutton is movable relative to the lower portion of the base between atleast a normal position and a depressed position, wherein the pushbutton actuates the valve assembly when in the depressed position toprovide a spray through the exit aperture; and a cover coupled to thebase, wherein the cover defines a push button opening that permitsaccess to the second end region of the body portion of the push buttonto allow depression of the push button by the user, wherein the coverand the base are movable relative to each other between at least alocked position such that the push button is restricted from moving intothe depressed position and an unlocked position such that the pushbutton is allowed to move into the depressed position, wherein the coverfurther defines a spray opening alignable with the exit aperture of theaperture portion when the cover is in the unlocked position, wherein thecover comprises a restraint structure, wherein the restraint structureis located below the aperture portion of the push button of the base torestrict the push button from moving into the depressed position whenthe cover is in the locked position.
 2. The actuator apparatus of claim1, wherein an upper surface of the restraint structure of the coverdirectly contacts a lower surface of the aperture portion of the pushbutton of the base to restrict the push button from moving into thedepressed position when the cover is in the locked position.
 3. Theactuator apparatus of claim 2, wherein the cover comprises a cylindricalinner wall portion lying along an axis of the actuator apparatus anddefining at least a portion of the push button opening, wherein at leasta portion of the restraint structure is located closer to the axis ofthe actuator apparatus than the cylindrical inner wall portion of thecover.
 4. The actuator apparatus of claim 3, wherein the cylindricalinner wall portion of the cover further defines: a first stop surfaceoperable with the aperture portion of the push button of the base tostop the cover from moving past the unlocked position; and a second stopstructure operable with the aperture portion of the push button of thebase to stop the cover from moving past the locked position.
 5. Theactuator apparatus of claim 3, wherein the lower portion of the basefurther comprises a first and second locking structure, wherein thecover further comprises an outer wall portion located further away fromthe axis of the actuator apparatus than the inner wall portion, whereinthe outer wall portion further comprises a male locking structurelocated on an interior surface of the outer wall portion of the cover,wherein the male locking structure of the outer wall portion engages thefirst female locking structure of the lower portion of the base when thecover is in the locked position, and wherein the male locking structureof the outer wall portion of the cover engages the second female lockingstructure of lower portion of the base when the cover is in the unlockedposition.
 6. The actuator apparatus of claim 4, wherein each femalelocking structure of the first and second female locking structures ofthe lower portion of the base comprise a first and second rib, whereineach rib of the first and second rib extend outwardly from the lowerportion of the base; and wherein the male locking structure of the outerwall portion of the cover comprises: a deflectable portion fordeflectably engaging the first rib of the first female locking structureof the lower portion of the base when the cover is moving into thelocked position and for deflectably engaging the first rib of the secondfemale locking structure of the lower portion of the base when the coveris moving into the unlocked position; and a rigid portion for engagingthe second rib of the first female locking structure of the base whenthe cover is moved into the locked position to stop the cover frommoving past the locked position and for engaging the second rib of thesecond female locking structure of the base when the cover is moved intothe unlocked position to stop the cover from moving past the unlockedposition.
 7. The actuator apparatus of claim 1, wherein the lowerportion of the base defines a push button aperture, wherein at least aportion of the body portion of the push button is located within thepush button aperture of the lower portion of the base when the pushbutton is in the depressed position.
 8. The actuator apparatus of claim1, wherein the base further comprises a spray opening shield portion forblocking the spray opening of the cover when the cover is in the lockedposition, wherein the spray opening shield extends upwardly from thelower portion of the base.
 9. The actuator apparatus of claim 1, whereinthe cover further comprises: an inner wall portion defining the pushbutton opening lying along the axis of the actuator apparatus; an outerwall portion located further away from the axis of the actuatorapparatus than the inner wall portion; and an annular flange located onan interior surface of the outer wall portion of the cover extendinginwardly towards the axis of the actuator apparatus, wherein the lowerportion of the base further comprises at least one deflectable coverretention rib for engaging the annular flange of the cover to couple thecover to the lower portion of the base.
 10. The actuator apparatus ofclaim 9, wherein the at least one deflectable cover retention rib of thelower portion of the base defines an annular gap extending at leastpartially around the lower portion of the base for receiving the annularflange of the cover to allow the cover and the base to move relative toeach other.
 11. The actuator apparatus of claim 1, wherein the base isfixed relative to the spray container, and further wherein the cover isrotatable relative to the base between the locked and unlockedpositions.
 12. The actuator apparatus of claim 1, wherein the covercomprises only one restraint structure.
 13. The actuator apparatus ofclaim 1, wherein the lower portion of the base of the actuator apparatusis coupled to a spray can, and wherein the spray can contains a liquidmaterial.
 14. The actuator apparatus of claim 13, wherein the liquidmaterial contained by the spray can comprises paint.
 15. An actuatorapparatus for a spray container, wherein the actuator apparatuscomprises: a base comprising: a lower portion couplable to the spraycontainer; and a push button depreciably attached to the lower portion,wherein the push button comprises: a body portion extending between afirst end region connectable to the lower portion of the base and asecond end region to be contacted for depression of the push button by auser; and an aperture portion extending radially from a region of thebody portion, wherein the push button is movable relative to the lowerportion of the base by depression of the push button by the user,wherein the aperture portion defines an exit aperture; and a covercoupled to the base, wherein the cover defines a push button openingthat permits access to the second end region of the body portion toallow depression of the push button by the user, wherein the cover andthe base are rotatably movable relative to each other between anunlocked position and a locked position, wherein the cover comprises acylindrical inner wall portion lying parallel to an axis of the actuatorapparatus, wherein the cylindrical inner wall portion defines at least aportion of the push button opening, wherein the cover further comprisesa restraint structure locatable below the aperture portion of the pushbutton of the base to restrict the push button from depression by theuser when in the locked position, wherein at least a portion of therestraint structure is located closer to the axis of the actuatorapparatus than the cylindrical inner wall portion of the cover, andwherein the cover defines a spray opening alignable with the exitaperture by rotating the cover and the base relative to each other whenin the unlocked position.
 16. The actuator apparatus of claim 15,wherein an upper surface of the restraint structure of the coverdirectly contacts a lower surface of the aperture portion of the pushbutton of the base to restrict the push button from depression by theuser.
 17. The actuator apparatus of claim 15, wherein the base is fixedrelative to the spray container.
 18. A method of manufacturing a coverfor an actuator apparatus having a base comprising a lower portion and acentrally-located push button depressibly attached to the lower portion,wherein the method of manufacturing comprises: providing a mold defininga cavity for forming the cover, wherein the cover defines acentrally-located push button opening that permits access to the pushbutton of the base when assembled with the base, wherein the covercomprises: an inner wall portion lying along an axis of the actuatorapparatus when assembled with the base, wherein the inner wall portiondefines at least a portion of the push button opening; an outer wallportion at a distance further away from the axis than the inner wallportion when assembled with the base, wherein the outer wall portiondefines a spray opening; and a restraint structure extending from theinner wall portion, wherein at least a portion of the restraintstructure is located closer to the axis of the actuator apparatus whenassembled than the inner wall portion of the cover, wherein the moldcomprises: a first mold portion defining a first molding surfacecorresponding to at least outer and inner wall portion surfaces of thecover facing a first direction and at least a lower surface of therestraint structure; and a second mold portion defining a second moldingsurface corresponding to at least outer and inner wall portion surfacesof the cover facing a second direction opposite from the first directionand at least an upper surface of the restraint structure; positioningthe first mold portion relative to the second mold portion such that thefirst molding surface of the first mold portion and the second moldingsurface of the second mold portion define the cavity of the mold forforming the cover; introducing moldable material into the cavity of themold; forming the cover from the moldable material within the cavity ofthe mold; moving the first mold portion relative to the second moldportion for removing the cover from the cavity of the mold; and removingthe cover from the cavity of the mold.
 19. The method of claim 18,wherein the cover comprises only one restraint structure.
 20. The methodof claim 18, wherein the forming the cover with the mold comprises atleast one of compression molding, injection molding, and transfermolding.